As the demand for lightweight materials grows, aluminum alloys are increasingly utilized across various industries. However, conventional fusion welding of medium-thick aluminum plates often results in defects. Friction stir welding (FSW), a solid-state joining process, effectively mitigates these issues. This study investigates double-sided FSW (DS-FSW) and single-sided FSW (SS-FSW) of 6061-T6 aluminum alloy through combined experiments and numerical simulations. The thermal cycles, stress distribution, material flow, microstructure evolution, and mechanical properties of the joints are systematically examined. Results demonstrate that DS-FSW joints exhibit a 31 % higher yield strength (228 MPa) compared to SS-FSW joints (174 MPa), along with superior tensile strength. However, both joint types show lower elongation than the base material, with DS-FSW slightly lower (4.43 %) than SS-FSW (4.87 %). Microhardness distribution is more heterogeneous in DS-FSW, with higher hardness in the heat-affected zone but lower in the nugget zone. Microstructural analysis reveals finer grains, higher dislocation density, and a greater proportion of high-angle grain boundaries in DS-FSW. The study innovatively proposes the hetero-deformation induced (HDI) strengthening mechanism in DS-FSW joints, offering valuable insights for optimizing welding processes for medium-thick aluminum plates in aerospace, automotive, and energy applications.
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